Electrical connectors and associated methods

Abstract

An article may include a blade and a leg portion, the blade extending from the leg portion in a first direction, the leg portion may include a shelf providing a first width from a first lateral edge to a second lateral edge, a first rounded protrusion at the first lateral edge and spaced from the shelf in a second direction opposite the first direction, a second rounded protrusion at the second lateral edge, the first and second rounded protrusions each providing a curvature at the respective lateral edges with a radius and providing a second width greater than the first width, a first rounded indentation between the first rounded protrusion and the shelf, and a second rounded indentation between the second rounded protrusion and the shelf, the first and second rounded indentations each providing a curvature at the respective lateral edges with the radius.

1 . An article, comprising:
 a blade; and   a leg portion, the blade extending from the leg portion in a first direction, the leg portion including:
 a shelf providing a first width from a first lateral edge to a second lateral edge, 
 a first rounded protrusion at the first lateral edge and spaced from the shelf in a second direction opposite the first direction, 
 a second rounded protrusion at the second lateral edge, the first and second rounded protrusions each providing a curvature at the respective lateral edges with a radius and providing a second width greater than the first width, 
 a first rounded indentation between the first rounded protrusion and the shelf, and 
 a second rounded indentation between the second rounded protrusion and the shelf, the first and second rounded indentations each providing a curvature at the respective lateral edges with the radius. 
   
     
     
         2 . The article of  claim 1 , wherein the radius is 0.10-0.20 mm. 
     
     
         3 . The article of  claim 2 , wherein the first width is 1.74-1.79 mm, and the second width is 1.82-1.87 mm. 
     
     
         4 . The article of  claim 1 , wherein the leg portion includes a first face providing the first and second lateral edges and a second face adjoined to the first face by a lateral surface. 
     
     
         5 . The article of  claim 4 , wherein a plane of symmetry extends through the article and is parallel with the first face and the second face. 
     
     
         6 . The article of  claim 5 , wherein the lateral surface provides a thickness, and the blade and the leg portion have the thickness. 
     
     
         7 . The article of  claim 1 , the blade extending in the first direction from a second leg portion, the second leg portion comprising:
 a second shelf providing the first width from a third lateral edge to a fourth lateral edge,   a third rounded protrusion at the third lateral edge and spaced from the second shelf in the second direction,   a fourth rounded protrusion at the fourth lateral edge, the third and fourth rounded protrusions each providing a curvature at the respective lateral edges with the radius providing the second width,   a third rounded indentation between the third rounded protrusion and the second shelf, and   a fourth rounded indentation between the fourth rounded protrusion and the second shelf, the third and fourth rounded indentations each providing a curvature at the respective third and fourth lateral edges with the radius.   
     
     
         8 . The article of  claim 7 , the blade extending in the first direction from a third leg portion, the third leg portion comprising:
 a third shelf providing the first width from a fifth lateral edge to a sixth lateral edge,   a fifth rounded protrusion at the fifth lateral edge and spaced from the third shelf in the second direction,   a sixth rounded protrusion at the sixth lateral edge, the fifth and sixth rounded protrusions each providing a curvature at the respective lateral edges with the radius and providing the second width,   a fifth rounded indentation between the fifth rounded protrusion and the third shelf, and   a sixth rounded indentation between the sixth rounded protrusion and the third shelf, the fifth and sixth rounded indentations each providing a curvature at the respective fifth and sixth lateral edges with the radius.   
     
     
         9 . A method, comprising:
 forming an article from flat sheet metal, the article comprising:
 a blade; and 
 a leg portion, the blade extending from the leg portion in a first direction, the leg portion including:
 a shelf providing a first width from a first lateral edge to a second lateral edge, 
 a first rounded protrusion at the first lateral edge and spaced from the shelf in a second direction opposite the first direction, 
 a second rounded protrusion at the second lateral edge, the first and second rounded protrusions each providing a curvature at the respective lateral edges with a radius and providing a second width greater than the first width, 
 a first rounded indentation between the first rounded protrusion and the shelf, and 
 a second rounded indentation between the second rounded protrusion and the shelf, the first and second rounded indentations each providing a curvature at the respective lateral edges with the radius. 
 
   
     
     
         10 . The method of  claim 9 , wherein the radius is 0.10-0.20 mm. 
     
     
         11 . The method of  claim 10 , wherein the first width is 1.74-1.79 mm, and the second width is 1.82-1.87 mm. 
     
     
         12 . A method, comprising:
 inserting an article into a slot in a header, the article comprising:
 a blade; and 
 a leg portion, the blade extending from the leg portion in a first direction, the leg portion including:
 a shelf providing a first width from a first lateral edge to a second lateral edge, 
 a first rounded protrusion at the first lateral edge and spaced from the shelf in a second direction opposite the first direction, 
 a second rounded protrusion at the second lateral edge, the first and second rounded protrusions each providing a curvature at the respective lateral edges with a radius and providing a second width greater than the first width, 
 a first rounded indentation between the first rounded protrusion and the shelf, and 
 a second rounded indentation between the second rounded protrusion and the shelf, the first and second rounded indentations each providing a curvature at the respective lateral edges with the radius, 
 wherein the slot has a third width less than the second width. 
 
   
     
     
         13 . The method of  claim 12 , wherein the radius is 0.10-0.20 mm. 
     
     
         14 . The method of  claim 13 , wherein the first width is 1.74-1.79 mm, and the second width is 1.82-1.87 mm. 
     
     
         15 . The method of  claim 14 , wherein the third width is 1.73-1.77 mm. 
     
     
         16 . The method of  claim 12 , wherein the first width is 1.74-1.79 mm, the second width is 1.82-1.87 mm, and the third width is 1.73-1.77 mm. 
     
     
         17 . The method of  claim 16 , wherein the header comprises Liquid Crystal Polymer, and the article comprises a copper zinc alloy. 
     
     
         18 . The method of  claim 12 , wherein the header comprises Liquid Crystal Polymer, and the article comprises a copper zinc alloy. 
     
     
         19 . The method of  claim 12 , wherein the leg portion includes a first face providing the first and second lateral edges and a second face adjoined to the first face by a lateral surface. 
     
     
         20 . The method of  claim 19 , wherein a plane of symmetry extends through the article and is parallel with the first face and the second face.